Methods and apparatus for a 3D-printed spring

Abstract

Various embodiments of the present technology may provide methods and apparatus for a 3D-printed spring. The 3D-printed spring may be formed from a plurality of toroidal elements spaced apart from each other and connected with a plurality of connectors. Each connector connects one toroidal element to a directly adjacent toroidal element.

The invention claimed is: 
     
       1. A 3D-printed spring, comprising:
 a plurality of toroidal elements aligned along a center axis that is common to each toroidal element, wherein each toroidal element is separated from a directly-adjacent toroidal element by a distance; and 
 a plurality of connectors, wherein each connector comprises:
 a first end connected to an inner surface of a first toroidal element at a first position relative to the center axis; and 
 a second end connected to an inner surface of a second directly-adjacent toroidal element at a second position relative to the center axis, wherein a midportion of each connector between the first and second ends extends across the distance separating the first and second toroidal elements. 
 
 
     
     
       2. The 3D-printed spring according to  claim 1 , wherein the plurality of aligned toroidal elements form a cylinder shape. 
     
     
       3. The 3D printed spring according to  claim 1 , wherein:
 the inner surface of each toroidal element faces the center axis; and 
 each toroidal element comprises an outer surface facing a direction opposite that of the inner surface. 
 
     
     
       4. The 3D-printed spring according to  claim 1 , wherein the number of connectors is one less than the number of toroidal elements. 
     
     
       5. The 3D-printed spring according to  claim 1 , wherein each connector, from the plurality of connectors, is cuboid-shaped. 
     
     
       6. The 3D-printed spring according to  claim 1 , wherein each connector, from the plurality of connectors, has a triangular prism shape. 
     
     
       7. The 3D-printed spring according to  claim 1 , wherein each connector, from the plurality of connectors, is cylinder-shaped. 
     
     
       8. A method for making a 3D-printed spring having a plurality of toroidal elements and a plurality of connectors with a 3D printer, comprising:
 executing a file with the 3D printer, wherein the file comprises instructions defining:
 an overall size of the 3D-printed spring; 
 a size, a shape, and a length of each connector; 
 a spacing between adjacent toroidal elements; 
 
 printing the 3D-printed spring according to the instructions, wherein the 3D-printed spring is printed as a single, continuous element and each connector comprises:
 a first end connected to an inner surface of a first toroidal element at a first position relative to a center axis of the plurality of toroidal elements; 
 a second end connected to an inner surface of a second directly-adjacent toroidal element at a second position relative to the center axis, wherein a midportion of each connector between the first and second ends extends across the distance separating the first and second toroidal elements. 
 
 
     
     
       9. The method according to  claim 8 , wherein the file containing instructions further relates to a print orientation of the 3D-printed spring. 
     
     
       10. The method according to  claim 8 , wherein the 3D-printed spring is printed without the use of support structures. 
     
     
       11. The method according to  claim 8 , wherein the 3D-printed spring is printed with a powder-based material. 
     
     
       12. The method according to  claim 8 , further comprising subjecting the 3D-printed spring to a post-processing treatment comprising at least one of: abrasion blasting, dyeing, graphite blasting, tumbler/mass finishing, polishing, automotive painting, electroplating, vapor smoothing, sanding, or chrome painting. 
     
     
       13. A clip, comprising:
 an inner spring comprising:
 a plurality of toroidal elements aligned along a center axis that is common to each toroidal element, wherein each toroidal element is spaced apart from a directly-adjacent toroidal element; and 
 a plurality of connectors, comprising:
 a first connector connected to:
 an inner surface at a first position relative to the center axis of a first toroidal element, from the plurality of toroidal elements; and 
 a first location on an inner surface at a second position relative to the center axis of a second toroidal element, from the plurality of toroidal elements; and 
 
 a second connector connected to:
 a second location on the inner surface of the second toroidal element at a third position relative to the center axis; and 
 a first location on an inner surface at a fourth position relative to the center axis of a third toroidal element, from the plurality of toroidal elements; 
 
 
 
 a first member connected to an outer surface of at least one toroidal element, the first member comprising a first grip portion and a first comb-shaped portion; and 
 a second member connected to an outer surface of at least one other toroidal element, the second member comprising a second grip portion and a second comb-shaped portion capable of interleaving with the first comb-shaped portion. 
 
     
     
       14. The clip according to  claim 13 , wherein the plurality of aligned toroidal elements form a cylinder shape. 
     
     
       15. The clip according to  claim 13 , wherein the inner surface faces inward toward the center axis and the outer surface faces outward away from the center axis. 
     
     
       16. The clip according to  claim 13 , wherein the number of connectors is one less than the number of toroidal elements. 
     
     
       17. The clip according to  claim 13 , wherein the first connector is arranged perpendicular to the second connector. 
     
     
       18. The clip according to  claim 13 , wherein the inner surface and the outer surface encircle the center axis. 
     
     
       19. The clip according to  claim 13 , wherein the first and second connectors are linear and rigid.